Process of making duplicate phonograph-records.



J. W. AYLSWORTH.

PROCESS OF MAKING DUPLICATE PHONOGRAPH RECORDS.

APPLICATION FILED SEPT. 17, 1909.

Patented May 6, 1913.

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- PROCESS OF MAKING DUPLICATE PHONOGRAPH RECORDS.

v APPLICATION FILED SEPT. 17,1909.

1,060,577. Patented May 6, 1913.

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1 I 9 J9, Z6 J x Q 'fl T "1.5 46 ZZ l [fizz/Zia)? @Zzggzwry M W JONAS W.AYLSWORTH, OF EAST ORANGE, NEW JERSEY, ASSIGNOR, BY MESNE ASSIGN- MENTS,TO THOMAS A. EDISON, INCORPORATED, OF WEST ORAN GE, NEW JERSEY, A

CORPORATION OF NEW JERSEY.

PROCESS -OIE MAKING DUPLICATE IPHONOG-R APE-RE(JORDS.v

Specification of Letters Patent.

Patented May 6, 1913.

Application filed September 17, 1909. Serial No. 518,272.

To all whom it may concern:

, Be it known that I, J ONAS W. AYLSWORTH, a citizen of the UnitedStates, and a resident of East Orange, in the county of Essex and Stateof New Jersey, have made a certain new and useful Invention in Processesof Making Duplicate Phonograph-Records, of which the following is adescription.

My invention relates to a process for making phonograph records in whichthe wearing surface is entirely of metal. The entire record may beconstituted of the metal, or

- the latter may be merely a shell provided with a backing of othermaterial. The process is particularly adapted to the manufacture ofcylindrical phonograph records, although it may be used for makingrecords of the disk type if desired.

Cylindrical sound records at the present time are generally made of awax-like material molded or cast within a hollow matrix, and diskrecords are formed of somewhat harder material employing considerablequantities of shellac, the impression being secured from a flat matrix.With both types of record the material is'subjected to considerable wearwhen used on a phonograph, and the production of a phonograph recordeasily and cheaply manufactured from metal or other substance havinggreater wearing qualities than the records now actually in use, isdesirable.

It has been proposed to make duplicate records of metal, but suchprocesses have been objectionable in that it has been necessary thereinto, destroy the matrix in order to liberate the metallic duplicate. Byan invention on which application for patent Serial No. 516,309 wasfiled by me September 4, 1909, a process was described and claimed bywhich it is possible readily to free the metallic duplicate from thematrix without injury to the latter, whereby the same may be used forthe production of an indefinite number of copies. By the. inventionforming the subject matter of the present application, the same resultis attained.-

The objects of my present invention, accordingly, are the commercialproduction of metallic duplicate sound records, the production of anovel and eflicient matrix for the production of such metallicduplicates, and the processes and sub-processes hereinafter moreparticularly described and claimed for producing the aforesaid metallicduplicates and the aforesaid matrix. I

The method hereinafter to be described v comprises four majoroperations. First, the manufacture of a master record. Second, themanufacture of a metallic master record. Third, the manufacture of amatrix of a large co-efficient of expansion from the metallic master,and, fourth, the manufacture of commercial metallic duplicate recordsfrom the matrix so formed.

The second step above mentioned is not, process described in myappresent in the plication Serial No. 516,309, above referred to, andthe matrix of large co-efiicient of expansion in the present process isspecifically different from' that employed in the process described inmy above mentioned application. The processes covered by the twoapplications, however, attain the same general object as above stated,and broad generic claims to the same, which might be made in eitherapplication, are inserted in application Serial No. 516,309 abovereferred to.

In order that the invention may be better understood, reference is madeto the accompanying drawings, of which Figure 1 is a central verticalsection through a master record, showing the formation of a temporarymatrix thereon. Fig. 2 is a central vertical section of apparatus forproducing the matrix within which the metallic positive records are tobe formed. Fig. 3 is a similar view of the matrix afterbeing removedfrom the apparatus of Fig. 2. Fig. 4 is a similar view showing apparatusfor producing a metallic deposit within the matrix to form the record orrecord wearing surface; and Fig. 5 is a similar view of the completerecord in its preferred form.

In all of these views, corresponding parts are designated by the samereference numerals.

The first step of the process consists in the obtaining of a masterrecord. This may be obtained in the same manner and may be of the samecomposition as is common in the art. The master record is designated inthe drawings by the reference character 1.

The second operation comprises the plating of the master record 1 withacoating of copper or zinc after application ofthe necessary conductivecoating of graphite or of gold by well known methods. This copper orzinc deposit forms a temporary matrix 2,-

as indicated in Fig. 1 of the drawings. The master record 1 isthen-removed from the zinc or cop per negative or temporary matrix, anda positive metallic master is formed therein by electro-deposition. Iprefer to form the metallic master of nickel. However, if the temporarymatrix is formed of zinc, the master which is formed therein may beeither of copper or of nickel, while if the temporary matrix is copper,the metallic master formed therein may be either nickel, iron, cobalt,silver or platinum. After suitably backing the nickel or other metallicmaster record, the copper or zinc temporary matrix 2 is removed bydissolving the same in an alkaline solution. This may be va solution ofcaustic soda or potash containing hydrogen peroxid if the temporarymatrix is of zinc. If the matrix to be dissolved is of copper, thesolution may be 10% cupric ammonia and 90% of strong ammonia. The cupricammonia is formed of 5% copper sulfate, 5% ammonium sulfate, and 90% ofstrong ammonia.

The third operation consists in casting a substance which has a highcoefficient of expansion with respect to copper, nickel and May 14,1909,or that described by Ba'ekeland in the Journal of Industrial and Engi-.nearing Chemistry, published by the American Chemical Society March,1909, page- 149. ,The matrix may be formed by casting: one of these orequivalent substances in theirpreliminary stages and heating. the samein the mold, with or without the application of pressure to produce bychemical action the;

final non-plastic condition of the material in which the latter is veryhard and durable,

is chemically inert, and is practically infusible-and insoluble in andotherwise not attacked by commercial acids. In this operation, the metalmaster record may be used as a core for the matrix. This operation isillustrated in Fig. 2 of the drawings, wherein the reference character 3designates the nickel or cop-per or other metallic master which has beenformed within. the temporary matrix 2 after the removal of the originalmaster record 1. T he metallic master 3 is backed with any suitablesubstance 4 and the same placed upon the hollow taper mandrel 5, whichacts as a centering device. The master 3 and backing 4 are placed uponthe base. 6 through which the taper mandrel 5 extends. The cylindricalmold 7 is also placed upon the base 6 which is provided with upwardlydirected flange 8 to retain the same. The cap 9 provided with downwardlydirected flange 10 is set upon the top of the mold 7. The cap 9 isprovided with openings 11 through which the material of which the matrixis to be formed may be poured.

If the matrix is to be formed from a phenol inert substance, may beapplied in any usual way. I prefer, however, to apply the heat from theinside of the matrix. Accordingly, in the drawing, the hollow tapermandrel 5 is illustrated as being provided with two pipe connections 15and 16 which pass through the wall of pressure chamber 12 and the lowerwall of mandrel'5 which -is entirely closed at its ends except for thetwo pipe connections. A circulation of steam or other hot gases throughthe inside of mandrel 5 may be maintained by means of theseconnections," and the heat necessary for transforming the substance ofwhich the matrix is composed into the final condensation product,thereby applied. The heat thus imparted to the "inside of mandrel 5 isconducted through backing 4 and metallic master 3 to matrix 14 which isthus given the highest heat on its inner or record'bearing surface. Thesubstance of which matrix 14 is composed hardens under heat treatment incontact with the record surface carried by master record 3 and forms aperfect negative thereof. After cooling, the matrix 3 by dissolving thesame in dilute acid. Or

the matrix might be separated, if desired,

from the metallic master '3 by forcible expansion of the matrix awayfrom the master 3 by the method described in my application Serial No.487,360, filed April 1, 1909.

A modification of the method so far described may be used, whichconsists in com pressing a celluloid or hard'rubber tube around themetal master 3 to form a matrix in place of the matrix 14 of a phenolcondensation product" hereinbefore described. In this case, thecelluloid or hard rubber tube is warmed sufliciently to render it plas-115 thus formed.is relieved of the metal master plating operation,

tic. The same may be removed from the metal master 3 when nearly cold byforcible expansion, as described in my application Serial No. 487,360,above referred to, or by dissolving out the metal master 3 as previouslydescribed. These steps result in the matrix shown in Fig. 3, the samehaving a high co-eflicient of expansion as compared with metals. Inorder to obtain a metallic record from a matrix of this character, theinterior and the lower end are first provided with an electricallyconductive coating, such as finely divided graphic or gold deposited incacao, and the matrix is then placed'in a holding frame suitable for theapplication of current therein in an electro-plating bath. This frame isillustrated in Fig. 4 and consists of upper and lower clamping plates 17and 18 held together by headed bolts 19 which are provided with wingnuts 20, the matrix resting upon contact plate 21 which is electricallyconnected by wire 22 with one bolt 19 and leading-in wire 23. Upper andlower rings 24 and 25 of insulating material are secured within plates17 and 18 respectively and conductive coatings are applied to such partsof these rings and of the plate 18 as it is intended shall receive ametallic deposit to form the shell or positive rec- 0rd 26.

The anode 27 of copper, zinc, iron, or other suitable metal is insertedwithin the frame and connected to leading-in wire 28, and the whole isplaced in a cold plating bath, and a thin coating or shell 26 of theanode metal is plated upon the matrix and adjacent parts, as shown. Theplating bath should be maintained at a constant temperature, preferablybelow 50 degrees F., as is described in my application Serial No.516,309, filed September 4, 1909. After the the frame and contents areremoved from the plating bath and washed, and the record removed fromthe matrix by warming the matrix and record sufiiciently to expand thematrix out of contact with the record 26, whereupon the same may beremoved from the matrix by direct longitudinal movement. Or the matrixmay be forcibly expanded within its elastic limit to separate the samefrom the record 26 without application of heat, as described in myapplication Serial No. 487,360, above referred to. The record may beused as formed, or, if desired, it may be suit-ably backedby well knownmeans with the backing 29. The matrix, after the removal of the metallicshell, is uninjured, and may be cleaned and dried and used in the mannerdescribed foran indefinite number of times for producing metallicrecords.

Having now described my invention, what I claim and desire to protect byLetters Patent is as follows;

1. The process ofduplicating phonograph pansion is rary matrix around amaster record, removing the master record, forming a metallic masterwithin the temporary matrix, removing the latter, forming a permanentmatrix around the metallic master of a substance whose coeflicient ofexpansion is relatively high as compared with 'metals, removing themetallic master, forming metallic duplicate records within saidpermanent matrix, applying heat to separate the records from the matrixby relative change of diameter, and removing the records from the matrixby relative longitudinal movement, substantially as described,

2. The process of duplicating phonograph records which consists incasting about a metallic master record a matrix of a substance whosecoefiicient of expansion is relatively high as compared with metals,removing the metallic master, forming metallic duplicate records withinsaid permanent matrix, applying heat to separate the records whichconsists in forming a temporecords from the matrix by relative change Iof diameter, and removing the records from the matrix by relativelongitudinal movement, substantially as described.

3. The rocess ofduplicating phonograph records 'w ich consists incasting about a metallic master record a matrix of a nonmetallicsubstance whose coeflicient of exrelatively high as compared withmetals, and which is not attacked by certain plating baths, removing themetallic master and depositing within the matrix formed a deposit of ametal from a plating-bath by which the substance of the matrix is notattacked to form a metallic duplicate record, substantially asdescribed.

4. The process of duplicating phonograph records which consists incasting about a metallic master record, a matrix of a non-me tallicsubstance whose coeflicient of expansion is relatively high as comparedwith metals, and which is not attacked by certain acids and certainplating baths, dissolving away the metallic master in an acid which doesnot attack the matrix, electrolytically depositing within the matrix adeposit of a metal from a plating bath by which the substance of thematrix is not attacked to form a metallic duplicate record, andseparating the latter 'from the matrix by relative change of diameter,substantially as described.

5. The process of duplicating phonograph records which consists incasting about a metallic master record a matrix of a non-metallicsubstance whose coefficient of expansion is relatively high as comparedwith metals, which is not attacked by certain acids, and which has ahigh melting point, dissolving away the metallic master in an acid whichdoes not attack the matrix, forming a metallic duplicate record withinthe matrix,.and applying heat to separate the record from the matrix byrelative change in diameter of the record and matrix, substantially asdescribed.

6. The process of duplicating phonograph records which consists incasting about a metallic master record a matrix of a nonmetallicsubstance whose coefficient of expansion isrelatively high as comparedwith metals and which is not attacked by certain plating baths,separating the matrix tively high as compared with certain metals,

separating the matrix thus formed from the metallic master, formingwithin the matrix a duplicate record of a metal Whose coefficient ofexpansion is low as compared with that of the matrix, and applying-heatto separate the record from the matrix by relative change in thediameters of the record and matrix, substantially as described.

8. The process of duplicating phonograph records which consists informing a master record of a substance having a high melting point,forming ina plastic condition about the latter a matrix of a substancewhich is plastic in one condition and which is trans formed by chemlcalaction 1nto another condition in which it is hard andinfusible bytreatment, applying the said heat treatment to cause the matrix tobecome hard while or the master record, and separating the master fromthe matrix, substantially as described.

9. The process of duplicating phonograph records which consists informing a master record of a substance having a high melting point,forming in a plastic condition about the latter a matrix of a phenolcondensation product, applying heat treatment to transform the matrixinto a hard, durable inert condition, and removing the mas-- tertherefrom, substantially as described.

10. The process of' duplicating phonotherefrom, forming a metallicpositive rec- 0rd within the matrix, applying heat to the record andmatrix and separating the same, substantially as described.

11. The process of duplicating phonograph records which consists informing a master record of a substance having a high melting point,forming in a plastic condi tion about the latter a matrix of a phenolcondensation product, applying heat treatment to transform the matrixinto a hard, durable inert condition, dissolving away the master,depositing electrolytically a metallic positive record within the matrixand separating the record from the matrix by causing relative change intheir diameters, substantially as described.

12. The process of duplicating phonograph records which consists informing a master record of a substance having a high melting point,forming in a plastic condi-. tion about the latter a matrix of asubstance which hardens by chemical action under heat treatment and hasa relatively high coefiicient of expansion as-compared with metals,heating the matrix to harden the same while on the master record, and remetals, introducing heat inside the matrix to harden the same while onthe master rec- 0rd, and removing the master record therefrom,substantially as described.

This specification signed and this 14th day of September, 1909.

' JONAS W. AYLSWORTH.

Witnesses DYER SMITH, JOHN M. CANFIELD.

witnessed Correction in Letters Patent No. 1,060,577.

It is hereby certified that in Letters 1913, upon the application ofJonas W. Aylsworth, of East Orange, New Jersey, for

an improvement in Processes of Making Duplicate Phonograph-Records, anerror appears in the printed specification requiring correction asfollows: Page 3, line 13,

for the word graphic read graphite, and that the said Letters Patentshould be read with this correction therein that the same may conform tothe record of the ease in the Patent Office.

Signedand sealed this 17th day of June, A. D. 1913.

[SEAL] G. O. BILLINGS,

Acting Commissioner of Patents.

Patent No. 1,060,577, granted May 6;

